Fluororesin Thermoplastic Elastomer Dynamic Vulcanization
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Solution Overview
Problem
Current thermoplastic polymer compositions, such as those using polypropylene and crosslinked EPDM, lack sufficient heat resistance, chemical resistance, flexibility, and processability, while those with fluororesins exhibit poor low-temperature properties and compression permanent deformation resistance.
Innovation Solution
A thermoplastic polymer composition comprising a fluororesin with a melting point of 120 to 310°C, dynamically vulcanized with a non-fluorine-containing cured rubber, forming a continuous phase and dispersion phase structure, respectively, to achieve enhanced heat resistance, chemical resistance, and processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If polypropylene resin is used as a matrix in TPV, then processability is improved, but heat resistance and chemical resistance deteriorate
Solution Approach 1:
The patent changes the matrix resin from polypropylene to fluororesin, fundamentally altering the material parameters to achieve both excellent heat resistance (maintaining properties at high temperatures) and chemical resistance (resistance to oils and chemicals), while maintaining sufficient processability through dynamic vulcanization
Solution Approach 2:
The patent creates a composite material system consisting of fluororesin matrix and dynamically vulcanized rubber particles, combining the high-temperature and chemical resistance of fluororesin with the flexibility and mechanical properties of rubber through a synergistic composite structure
2Reliability
If fluororesin is used as a matrix in TPV, then heat resistance and chemical resistance are improved, but low-temperature property, flexibility and compression permanent deformation resistance deteriorate
Solution Approach 1:
The patent creates a composite material system consisting of fluororesin matrix and dynamically vulcanized rubber particles, combining the high-temperature and chemical resistance of fluororesin with the flexibility and mechanical properties of rubber through a synergistic composite structure
Solution Approach 2:
The patent applies local quality by having the rubber particles distributed within the fluororesin matrix, where the rubber phase provides flexibility and low-temperature properties locally, while the fluororesin matrix provides heat resistance and chemical resistance, creating a material with spatially differentiated functions
3Reliability
If conventional curing process is used for rubber, then heat resistance is improved, but processing time increases and post-process melt-adhesion becomes impossible
Solution Approach 1:
The patent merges the molding process and crosslinking process into a single dynamic vulcanization step, where rubber particles are crosslinked within the thermoplastic matrix during extrusion or injection molding, eliminating the need for separate curing steps and enabling post-process melt-adhesion while maintaining heat resistance
Solution Approach 2:
The patent employs dynamic vulcanization, where the rubber is crosslinked under dynamic mixing conditions during processing, creating a unique structure where crosslinked rubber particles are dispersed in the thermoplastic matrix, combining the advantages of both thermosetting (heat resistance) and thermoplastic (reprocessability) materials
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition exhibits excellent heat resistance, chemical resistance, flexibility, and processability, with improved mechanical performance and mold-processability, and can be used in various applications including electric wire jackets and laminates.
Implementation Method 1
crosslinking is conducted while a thermoplastic resin such as polypropylene resin, an uncrosslinked crosslinkable rubber and a crosslinking agent are all together melt-kneading in an extruder
Implementation Method 2
so called dynamic vulcanization technique has been developed such that crosslinking is conducted while a thermoplastic resin such as polypropylene resin, an uncrosslinked crosslinkable rubber and a crosslinking agent are all together melt-kneading in an extruder
Implementation Method 3
the fluororesin (A) comprises a fluorine-containing ethylenic polymer (a), and the non-fluorine-containing cured rubber (B) is at least one rubber (b) which is at least partially crosslinked
Data Source
AI summary
The invention provides a thermoplastic polymer composition which has both excellent heat resistance and chemical resistance, and also has flexibility and excellent processability. The present invention is a thermoplastic polymer composition comprising a fluororesin (A) and non-fluorine-containing cured rubber (B), wherein the fluororesin (A) comprises a fluorine-containing ethylenic polymer (a), and the non-fluorine-containing cured rubber (B) is at least one kind of rubber (b) which is at least partially crosslinked.